AS9100D Certified

Precision
Manufacturing

From advanced composite layup to precision CNC machining — Carson Helicopters produces aerospace-grade components for rotary wing platforms under one roof in Perkasie, Pennsylvania.

Composite Manufacturing

Advanced Composite
Fabrication

Carson's composite manufacturing capability was built around the demands of rotor blade production — one of the most structurally demanding applications in aerospace. That same infrastructure is available for custom composite parts and structures.

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Hand Layup & Prepreg Processing

Skilled composite technicians perform hand layup of carbon fiber, fiberglass, and hybrid laminates using both wet layup and prepreg materials for structural and aerodynamic components.

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Custom Tooling & Mold Fabrication

In-house tooling design and fabrication for new composite components. Carson builds its own molds and fixtures, enabling rapid prototyping and low-volume production without outside lead times.

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Fatigue & Structural Testing

On-site fatigue rig for full-scale component testing. New composite designs are validated in-house before entering certification — reducing schedule risk and cost.

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FAA PMA & STC-Backed Production

Parts manufactured under FAA Parts Manufacturer Approval (PMA) since 2013. Carson's 35+ STC library supports certified modifications across the S-61 family.

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Composite blade manufacturing
1,000+ blades Composite Blades Produced
35+ STCs FAA Certified Modifications
Precision Machining

CNC Machining &
Part Production

Carson's machining shop produces precision metal components for helicopter overhaul, modification, and new part programs. With in-house capability spanning turning, milling, and sheet metal fabrication, Carson reduces dependence on outside vendors and controls quality at every step.

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CNC Turning & Milling

Multi-axis CNC machining for precision helicopter components — brackets, housings, shafts, and structural fittings machined to aerospace tolerances.

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Sheet Metal Fabrication

In-house sheet metal shop for airframe panels, fairings, brackets, and structural repairs. Forming, cutting, and finishing under one roof.

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FAA PMA Parts Production

Machined parts produced under FAA PMA authorization — providing operators with certified, traceable replacement parts for S-61 components no longer available from the OEM.

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Engineering & Reverse Engineering

Carson's engineering team supports custom part development from scratch or from existing hardware — including reverse engineering of obsolete components to restore aircraft to full airworthiness.

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Carson Helicopters CNC machining shop floor
Quality Standards

Built to
Aerospace Standards

Every part that leaves Carson's facility — whether composite or machined — is produced under a quality management system built for the demands of aerospace and defense.

AS9100D Certified

Aerospace Quality Management System certification — the global standard for aviation, space, and defense manufacturing organizations.

FAA Part 145 Repair Station

Certified for S-61 and UH-60 airframe and all dynamic components — ensuring manufactured parts meet the same standards as OEM production.

FAA PMA Since 2013

Parts Manufacturer Approval authorizes Carson to produce and sell certified replacement parts — providing operators with traceable, conforming components.

Sikorsky Fleet Support Authorization

Authorized OEM-level support for the S-61 family — backed by Sikorsky's own engineering documentation and approval process.

In-House Testing

Fatigue rig, structural test fixtures, and flight test capability on-site — manufactured parts validated before entering service, not after.

Custom Program Support

Open to custom manufacturing partnerships with OEMs, government agencies, and MRO operators requiring low-volume aerospace-grade production.

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